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TOYOTA AND LEXUS HIGHLANDER HYBRID REMOVAL AND INSTALLATION MANUAL

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Filed Under (Toyota Manuals) by admin on 08-03-2012

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Engine and Vehicle Identification Chart………………………………………..4-2 General Engine Specifications………4-2 Engine Tune-Up Specifications……..4-2 Capacities ………………………………….4-3 Valve Specifications …………………….4-3 Crankshaft and Connecting Rod Specifications……………………..4-3 Camshaft and Bearing Specifications ……………………………4-4 Piston and Ring Specifications……..4-4 Torque Specifications………………….4-4 Wheel Alignment ………………………..4-5 Tire, Wheel and Ball Joint Specifications ……………………………4-5 Brake Specifications ……………………4-5 Scheduled Maintenance Intervals……………………………………4-6 STEERING AND SUSPENSION ………………4-28 A Air Bag…………………………………….4-28 Disarming ……………………………4-28 Precautions ………………………….4-28 Alternator …………………………………..4-7 B Brake Caliper ……………………………4-30 Removal And Installation……….4-30 C Camshaft and Valve Lifters…………4-14 Inspection ……………………………4-16 Removal & Installation…………..4-14 CV-Joints………………………………… 4-24 Overhaul ……………………………..4-24 Cylinder Head …………………………..4-10 Removal & Installation…………..4-10 D Disc Brake Pads………………………..4-32 Removal And Installation……….4-32 E Engine Assembly ………………………..4-7 Removal & Installation…………….4-7 Exhaust Manifold ………………………4-12 Removal & Installation…………..4-12 F Front Crankshaft Seal………………..4-14 Removal & Installation…………..4-14 Front Halfshaft………………………….4-23 Removal & Installation…………..4-23 Front Strut ……………………………….4-28 Removal & Installation…………..4-28 Front Wheel Bearing………………….4-29 Fuel Filter ………………………………..4-21 Fuel Injector……………………………..4-22 Removal & Installation…………..4-22 Fuel Pump ……………………………….4-21 Removal & Installation…………..4-21 Fuel System Pressure………………..4-21 Relieving ……………………………..4-21 H Heater Core………………………………..4-7 Removal & Installation…………….4-7 Hybrid Transaxle Assembly…………4-22 Removal & Installation…………..4-22 I Ignition Timing ………………………….. 4-7 Adjustment…………………………….4-7 Intake Manifold …………………………4-11 Removal & Installation…………..4-11 L Lower Ball Joint………………………..4-29 Removal & Installation…………..4-29 Lower Control Arm……………………4-29 Removal & Installation…………..4-29 O Oil Pan…………………………………….4-18 Removal & Installation…………..4-18 Oil Pump …………………………………4-18 Removal & Installation…………..4-18 P Pinion Seal ………………………………4-27 Removal & Installation…………..4-27 Piston and Ring………………………..4-21 Positioning ………………………….4-21 Power Rack And Pinion Steering Gear…………………………..4-28 Removal & Installation…………..4-28 R Rear Halfshaft………………………….. 4-24 Removal And Installation……….4-24 Rear Main Seal…………………………4-19 Removal & Installation…………..4-19 Rear Strut…………………………………4-28 Conventional Strut Overhaul…..4-28 Removal And Installation……….4-28 Rear Traction Motor…………………..4-22 Removal & Installation…………..4-22 Rear Wheel Bearing…………………..4-29 Removal And Installation……….4-29 T Timing Belt ………………………………4-19 Removal & Installation…………..4-19 V Valve Lash ……………………………….4-17 Adjustment…………………………..4-17 W Water Pump ……………………………..4-10 Removal & Installation………..

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2001 Dodge Durango BLOWER MOTOR RELAYS REPAIR MANUAL

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Filed Under (Dodge Manuals) by admin on 13-02-2012

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BLOWER MOTOR RESISTOR 1. Disconnect negative battery cable. Disconnect blower motor resistor harness connector. Using DVOM, check for continuity between all blower motor resistor terminals. If continuity exists between all terminals, go to next step. If continuity does not exist between all terminals, replace faulty blower motor resistor. 2. Check for open or short in circuits between blower motor resistor and heater control panel. Also check for open or short in wire between blower motor resistor and blower motor. BLOWER MOTOR SWITCH 2000 Dakota, 2000 Durango & 2000-01 Ram Pickup 1. Remove Power Distribution Center (PDC) cover. Using DVOM, check for battery voltage at PDC fuse No. 5 (40-amp) on Dakota and Durango; PDC fuse No. 12 (40-amp) on Ram Pickup. If battery voltage exists, go to next step. If battery voltage does not exist, check for open in Red wire between battery and underhood PDC. If Red wire is okay, replace underhood PDC. 2. Disconnect negative battery cable. Remove heater control panel. See HEATER CONTROL PANEL under REMOVAL & INSTALLATION. Disconnect heater control panel cable, electrical and vacuum connectors as necessary. Using DVOM, check for continuity between heater control panel harness connector terminal No. 7 (Black wire on Dakota and Durango; Black/Orange on Ram Pickup) and ground. See Fig. 5 . If continuity exists, go to step 4 . 3. If continuity does not exist, repair open in Black wire or Black/Orange wire between heater control panel 2001 Dodge Durango 2000-01 HEATER SYSTEMS’ ‘RWD Trucks & Vans harness connector terminal No. 7 and ground connector located at lower right corner of instrument panel (Dakota and Durango) or behind center of instrument panel (Ram Pickup). 4. Place heater mode control knob to any position except OFF. Using DVOM, check for continuity between heater control panel terminal No. 7 and terminals No. 3, 4, 5 and 6 while rotating blower motor switch. See Fig. 5 . 5. If continuity does not exist at any terminal, replace faulty heater control panel. If continuity exists as specified, check for open in circuits between heater control panel and blower motor resistor. Also check for an open in circuit between heater control panel and blower motor. See WIRING DIAGRAMS . Fig. 5: Identifying Heater Control Panel Blower Switch Connector Terminals (2000 Dakota & Durango Are Shown; Ram Pickup Is Similar) Courtesy of CHRYSLER CORP. Ram Van/Wagon 1. Disconnect negative battery cable. Remove heater control panel. See HEATER CONTROL PANEL under REMOVAL & INSTALLATION. Disconnect heater control panel harness connectors. Using DVOM, check for continuity between heater control panel C3 harness connector terminal “C” (Black wire) and ground. See Fig. 6 . If continuity exists, go to next step. If continuity does not exist, repair open in Black wire between heater control panel and ground connector located at lower right of steering column. 2. Place heater mode control selector to any position, except OFF. Using DVOM, check for continuity between appropriate terminals of heater control panel, for C3 connector terminals “B” (Violet wire) and “C” (Black wire). If continuity exists through heater control panel, go to next step. If continuity does not exist, replace faulty heater control panel assembly. 3. Using DVOM, check for continuity between heater control panel C3 connector terminal “B” (Violet wire) and C1 connector terminal “E” (Violet wire). See Fig. 6 . If continuity exists, go to next step. If continuity does not exist, repair open in Violet wire between heater control panel C3 and C1 connectors.

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2004 Pontiac Grand Prix Blower Motor Inoperative or Intermittent, Blower Speed May Drop or Blower Continues to Run After Key Off (Install a Capacitor at Blower Motor Control Module Connector) Service Manual

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Filed Under (Pontiac Manuals) by admin on 27-02-2011

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Technicians are to install a capacitor, P/N 25073556, at the blower motor control module connector using the following procedure: 1. Disconnect the negative cable from the battery. Refer to the Battery Negative Cable Disconnect/Connect procedure in the Engine Electrical section of SI. 2. Remove the right closeout/insulator panel. Refer to the Closeout/Insulator Panel Replacement-Right procedure in the Instrument Panel, Gages and Console section of SI 3. Disconnect the wire harness connector to the blower motor control module. 4. Install a capacitor, P/N 25073556, into the blower motor control module connector using the following steps. Refer to the illustration above to locate the positive and negative leads of the capacitor. Refer to the Splicing Copper Wire Using Splice Clips procedure in the Wiring Systems section of SI (Document ID #303646) for more information on using splice clips. 5. If the customer concern was of a blower motor that continues to run after key off, then replace the blower motor control module and install the capacitor . Refer to the blower motor control module Replacement procedure in the HVAC section of SI. This condition is the only time you need to replace the blower motor control module. 6. Reconnect the blower motor control module connector. 7. Install the right closeout/insulator panel. Refer to the Closeout/Insulator Panel Replacement- Right procedure in the Instrument Panel, Gages and Console section of SI. 8. Reconnect the negative cable to the battery. Refer to the Battery Negative Cable Disconnect/Connect procedure in the Engine Electrical section of SI. 9. Verify proper operation of the blower motor.

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2005 Chevy Truck Silverado 1500 2WD Blower Motor Resistor Replacement

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Filed Under (Chevy Manuals) by admin on 29-04-2012

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Blower Motor Resistor Replacement Notes BLOWER MOTOR RESISTOR REPLACEMENT REMOVAL PROCEDURE 1. If equipped, remove the IP sound insulator. 2. Disconnect the electrical connection from the blower motor . 3. Disconnect the electrical connection from the blower motor resistor 4. Remove the blower motor resistor retaining screws. 5. Remove the blower motor resistor. INSTALLATION PROCEDURE 1. Install the blower motor resistor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the blower motor resistor retaining screws. Tighten Tighten the screws to 1.6 N.m (14 lb in) . 3. Connect the electrical connection to the blower motor resistor. 4. Connect the electrical connection to the blower motor . 5. If equipped, install the IP sound insulator.

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2001-2004 FORD Taurus WATER IN THE BLOWER CASE—BLOWER MOTOR SERVICE PROCEDURE

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Filed Under (Ford Manuals) by admin on 14-06-2011

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SERVICE PROCEDURE 1. Access blower motor and resistor per the Workshop Manual Sections 412-02 and 412-04. Inspect for evidence of water/corrosion. If water/corrosion are found or parts have failed, replace per Workshop Manual (blower motor 1F1Z-19805-AA and resistor F6DZ-19A706-AA). 2. Visually inspect the Cowl Vent Screen located under the RH windshield wiper to verify if the Figure 1 – Article 04-15-3 screen is fully seated. Inspect the rubber seal on the vent screen which should be fully seated 5. Locate the tape as shown (Figure 2). Remove against the windshield. If the cowl vent screen the tape and apply Clear Silicone Rubber is not fully seated and appears warped, it must TA-32 to the small hole as shown (Figure 2). be replaced (4F1Z-54018A16-BAA) 3. Remove the cowl vent screen per the vehicle model years and build date information. Workshop Manual Section 412-01 Pollen Filter Removal and inspect the cabin filter to confirm ISSUE it is fully seated. Re-seat the filter as Some vehicles built between 5/1/2001 and necessary. Inspect rain-hat base to make sure 12/15/2003 may exhibit water in the blower case or it is secure and sealed to the body. Reposition on the passenger side floor, an inoperative climate and reseal as necessary using Clear Silicone control blower motor, a motor that operates on high Rubber TA-32. speed only, and/or a blower motor resistor failure. 4. Remove the foam sealant expulsion at lower front outboard corner base of the rain-hat ACTION (Figure 1). Inspect and seal cowl area and install Rain-Hat Extension Seal. Inspect and replace blower motor and/or blower motor resistor if there is evidence of water/corrosion. Refer to the following Service Procedure for details.

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2002 Chrysler Voyager LX Power Windows TROUBLE SHOOTING/ SYSTEM TESTS

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Filed Under (Chrysler Manuals) by admin on 19-11-2011

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ALL WINDOWS INOPERATIVE 1. Check power window system circuit breaker and fuse. See TROUBLE SHOOTING . Replace components as necessary. If components are okay, go to next step. 2. Remove driver’s power window switch. See POWER WINDOW SWITCH under REMOVAL & INSTALLATION. Turn ignition on. Using test light, connect ground lead to harness connector terminal No. 13 (Black/Brown wire). Check for voltage by touching test light probe to harness connector terminals No. 9, 11 and 14 (all White/Pink wires). 3. If test light does not illuminate, check power and ground circuits. See WIRING DIAGRAMS . If test light illuminates, ground circuit and power circuit between battery and switch are okay. Check switch and motor. See POWER WINDOW SWITCH and POWER WINDOW MOTOR under COMPONENT TESTS. COMPONENT TESTS VENT WINDOW MOTOR 1. Remove “D” pillar trim panel. See “D” PILLAR TRIM PANEL under REMOVAL & INSTALLATION. 2. Disconnect power vent window motor wire connector from body harness. 3. Using 2 jumper wires, connect one to a battery (+) source and the other to a good ground (-). 4. Connect the negative (-) jumper probe to one of the motor connector terminals. 5. Momentarily touch the positive (+) jumper probe to the other motor connector terminal. When the positive probe is connected, the motor should rotate in one direction to either move window open of closed. If window is all the way open or closed the motor will grunt and the crank system will flex when actuated in the one direction. Reverse jumper probes at the motor connector terminals and window should now move in the opposite position to verify full operation. If motor grunts and does not move with the motor connected in both directions, verify that crank system is not binding. POWER WINDOW MOTOR 1. Remove door trim panel and sound pad. See DOOR TRIM PANEL under REMOVAL & INSTALLATION. 2. Disconnect power window motor wire connector from door harness. 3. Using 2 jumper wires, connect one to a battery (+) source and the other to a good ground (-). 4. Connect the negative (-) jumper probe to one of the motor connector terminals. POWER WINDOW SWITCH 1. Remove window switch from door trim panel. See POWER WINDOW SWITCH under REMOVAL & INSTALLATION. Using an ohmmeter, check switch continuity. See appropriate WINDOW SWITCH CONTINUITY table. See Fig. 1 or Fig. 2 . 2. If the results are NOT OK, replace the drivers side window lift switch. 3. Test passenger door switch for continuity. 4. If the results are not OK, replace the switch. The power window master switch has a Auto-Down feature. The switch is equipped with 2 detent positions when actuating the power window OPEN. The first detent position allows the window to roll down and stop when the switch is released. The second detent position actuates an integral express roll down relay that rolls the window down after the switch is released. When the express down circuit senses stall current (window has reached end of down travel), the switch will turn current off to the motor. The AUTO feature can be cancelled by actuating the switch UP or DOWN while window is in motion. If the electronic circuit in the switch fails to detect a stall current, the auto down circuit will time out within 9 to 13 seconds.

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2004 FORD F150 Door Window Glass-Rear SuperCrew REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 27-06-2012

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REMOVAL AND INSTALLATION 3. Remove the parts in the order indicated in the Door Window Glass — Rear, following illustration and table. SuperCrew To remove individual parts, only carry out the listed steps: NOTE: LH side is shown. RH side is similar. Part Steps 1. Remove the rear door trim panel. For additional Rear door window glass 1-4 information, refer to Section 501-00. Rear door window glass 1-7 regulator 2. Remove the rear door-mounted speaker. For additional information, refer to Section 415-00. Rear door window glass 1, 8 top run ItemPart NumberDescription ItemPart NumberDescription 4 1625712/ Rear door window glass 1 1625766/ Interior moulding (RH/LH) 1625713 (RH/LH) 1625767 Removal Note 2 1627458/ Watershield (RH/LH) 5 180103-14632 Window motor electrical 1627459 Removal Note connector Installation Note 6 W505421-S301Window regulator bolts (5 3 — Rear door window req’d) glass-to-regulator bolt (2 req’d) 7 1627000/ Window regulator assembly Removal Note 1627001 (RH/LH) (Continued) (Continued) Copyright © 2003, Ford Motor Company Last updated: 6/14/2004 2004 F150, 12/2003 501-00-2 501-00-2 Body System — Exterior REMOVAL AND INSTALLATION (Continued) Item 4: Rear Door Window Glass Removal ItemPart NumberDescription Note 8 1625766/ Rear door window glass top 1. Pull the glass out through the top inboard side 1625767 run (RH/LH) Removal Note of the door. 9 1625596/ Exterior moulding (right side) Item 8: Rear Door Window Glass Top Run 1625597 (RH/LH) Removal Note 4. To install, reverse the removal procedure. 1. Remove the glass top run through the top opening of rear door. Item 2: Watershield Removal Note Item 2: Watershield Installation Note 1. Do not tear or damage the watershield during disassembly. 1. Watershield must be installed so that edges have a weatherproof seal. Item 3: Rear Door Window Glass-to-Regulator Bolts Removal Note NOTE: Some vehicles may use rivets to attach the glass to the regulator. 1. If removing only the rear door glass regulator assembly and motor, secure the rear door glass in the full up position with tape.

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1996-2000 Honda Civic Door Panel REMOVAL And INSTALLATION Manual

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Filed Under (Honda Manuals) by admin on 05-06-2012

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Honda Door Panel 96-00 Civic REMOVAL & INSTALLATION Remove the screw from behind the interior door handle Slide out the door handle trim as shown Removing the door panel from the passenger side door View of the inside of the door, panel removed 1. Remove the screw from the door handle trim. 2. Slide the handle assembly forward and out to access the lock rod clip. 3. Release the clip 4. Disconnect the door lock switch 5. Remove the door opener handle assembly. 6. Carefully pry at the small opening on the bottom of the speaker grill. 7. Remove the speaker grille. 8. Remove the speaker mounting screws. 9. Detach the electrical connector and remove the speaker. 10. Remove the screws in the armrest. 11. Remove the center from the trim clip at the upper front of the door panel and remove the clip. 12. Using a suitable trim panel removal tool, unsnap the door panel from the door frame. 13. Carefully lift the door panel up and away from the door frame. To install: 14. Installation is the reverse of the removal procedure. Honda Civic/Del Sol 1996-2000 Electric Window Motor REMOVAL & INSTALLATION 1. Remove the regulator from the door assembly. 2. Except for the rear doors, drill a hole through the regulator sector gear and backplate. Install the bolt and nut to lock the sector gear in position. Be careful not to drill a hole closer than 7/ 16 in. (11mm) from the edge of the sector. Also, do not drill through the lift arm attaching portion of the sector gear, or the joint integrity will be jeopardized. 3. Drill out the ends of the motor attaching rivets using a 1/ 4 in. (6mm) bit. 4. Remove the motor and the remaining portions of the rivets from the regulator. Except for the rear doors, one rivet will not be accessible until assembly. Regulator and motor assembly—except rear doors Secure the rivets by collapsing the rivet ends using a ball peen hammer To install: 5. Position the new motor to the regulator. With the aid of an assistant, install new rivets by collapsing or crushing the rivet ends using a ball peen hammer. 6. Except for the rear doors, once two of the three rivets have been installed, remove the bolt securing the sector gear to the backplate, then use an appropriate electrical source (such as the vehicle’s window motor harness) to rotate the regulator, providing access to the remaining rivet. 7. Except for the rear doors, use a flat nosed rotary file to grind off one sector gear tooth from the side which does not contact the driven gear. This is necessary to reach the remaining rivet. Remove the old rivet, then install the remaining new rivet. 8. Install the regulator to the door assembly.

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1995 Mazda MX-6 FRONT DISC BRAKE PADS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Mazda Manuals) by admin on 16-02-2012

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REMOVAL & INSTALLATION FRONT DISC BRAKE PADS Removal & Installation 1. Raise and support front of vehicle. Remove front wheel assemblies. Remove lower lock pin/guide bolt. See Fig. 2 . Pivot caliper upward and support using rope. 2. Remove pads, shims, guide plates or pad guides and “V” springs (if equipped). Replace pad if lining thickness is less than specified. See MINIMUM PAD LINING SPECIFICATIONS (FRONT) table. 3. To install, reverse removal procedure. Use Disc Brake Expander (49-0221-600C) and an old pad to push piston fully inward to install disc pads. Fig. 2: Exploded View Of Front Brake Disc Assembly Courtesy of MAZDA MOTORS CORP. MINIMUM PAD LINING SPECIFICATIONS (FRONT) Application Thickness In. (mm) MX-6, 626 FRONT DISC BRAKE CALIPER Removal & Installation Raise and support front of vehicle. Remove front wheel assemblies and disconnect brake hose. Plug all openings. Remove front disc brake pads. See FRONT DISC BRAKE PADS . Remove remaining mounting bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Bleed air from system. FRONT BRAKE ROTOR Removal & Installation 1. Raise and support front of vehicle. Remove front wheel assemblies. Remove front disc brake caliper with brake hose connected. See FRONT DISC BRAKE CALIPER . Wire caliper aside. Remove rotor-to-hub screws (if equipped). Remove rotor. 2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS table. To install, reverse removal procedure. REAR DISC BRAKE PADS Removal & Installation 1. Raise and support rear of vehicle. Remove rear wheel assemblies. Release parking brake and disconnect parking brake cable from caliper. Remove manual adjustment gear concealment plug from caliper. See Fig. 3 . Insert an appropriate size Allen wrench through hole and turn manual adjustment gear counterclockwise to retract caliper piston. 2. Remove upper guide bolt from caliper. Rotate caliper downward and support using wire. Remove “M” springs. Remove pads, shims and guide plates. Replace pad if lining thickness is less than .04″ (1.0 mm). 3. To install, reverse removal procedure. Turn manual adjustment gear clockwise until brake pads slightly touch rotor. Turn manual adjustment gear back 1/3 turn.

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2006 Ford Pickup F350 Super Duty Intake Manifold Component Removal And Installation Manual

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Filed Under (Ford Manuals) by admin on 13-05-2011

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Removal All vehicles 1. Remove the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES . 2. Remove the cooling fan stator. For additional information, refer to ENGINE COOLING . 3. Remove the degas bottle. For additional information, refer to ENGINE COOLING . 4. Disconnect the upper radiator hose. Fig. 23: Locating Upper Radiator Hose Courtesy of FORD MOTOR CO. Fig. 24: Locating Turbocharger-To-CAC Duct Courtesy of FORD MOTOR CO. 5. Remove the turbocharger-to-CAC duct Vehicles with dual generators 6. Remove the accessory drive belt. Fig. 25: Rotating Drive Belt Tensioner Clockwise Courtesy of FORD MOTOR CO. 7. Remove the bolt and the accessory drive belt tensioner. Fig. 26: Locating Accessory Drive Belt Tensioner Bolt Courtesy of FORD MOTOR CO. 8. Remove the accessory drive belt. Fig. 27: Rotating Accessory Drive Belt Tensioner Courtesy of FORD MOTOR CO. 9. Remove the bolts, bracket and accessory drive belt idler pulley. Fig. 28: Locating Bracket And Accessory Drive Belt Idler Pulley Bolts Courtesy of FORD MOTOR CO. 10. Remove the bolts and the accessory drive belt tensioner. Fig. 29: Locating Accessory Drive Belt Tensioner Bolts Courtesy of FORD MOTOR CO. 11. Disconnect the wiring harness retainer, generator electrical connector and B+ wire. Fig. 30: Locating Wire Retainer And Generator Electrical Connectors Courtesy of FORD MOTOR CO. 12. Remove the bolts and the generator with mounting bracket.

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